The optimization of heat-sealing process parameters, including time, temperature, and pressure, was performed on a monolayer linear low-density polyethylene (LLDPE) film. The seal properties examined for each process condition were: seal initiation temperature (T-si), plateau initiation temperature (T-pi), final plateau temperature (T-pf), plateau seal strength (SSp), and failure mode. Increasing dwell time enhanced seal strength. However, it was found that the rate of this enhancement is different for each interval of dwell time. A narrow temperature plateau was observed for dwell times lower than 0.4 s and higher than 2 s, while in between a broad temperature window was observed. The pressure shows its influence up to the stage of wetting. And after providing the intimate contact between two film layers, additional increase in pressure does not enhance seal strength significantly. A 3D mapping of process safety zone was introduced for seal strength in the range of heat seal process variables for the very first time. The analysis of this 3D representation revealed that seal strength has a linear correlation with the square root of dwell time. In addition, the interfacial bond strength was shown to be proportional to the fraction of melted crystals. It was found that this fraction is determined by dwell time and temperature. Topography and morphology of surfaces after peeling revealed enlargement of fibrillar morphology to taller failure fracture complex shapes. Extensive roughness analysis on film surfaces after peeling found the much rougher surfaces after breakage of strong bonding.